Installation Guide 2016 Kawasaki ZX10-R Exhaust Kit!! THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE RACING AND IS NOT INTENDED FOR HIGHWAY USE!!
Congratulations on the purchase of your new TaylorMade underbelly exhaust kit for your 2011 Kawasaki ZX-10R. All components of your new exhaust are fabricated from thin wall stainless steel which will ensure that it will never rust. T Congratulations on the purchase of your new TaylorMade underbelly exhaust kit for your ZX10R. All components of your new exhaust are fabricated from thin wall stainless steel so it will never rust. The black finish is a baked-on ceramic coating which only requires washing with soap and water to help keep it clean. To keep your carbon fiber looking new, we recommend a regular application of Turtle Wax s Color Magic in black. Any knowledgeable mechanic with a basic set of tools should be able to install the kit. If you have any doubts in your mechanical abilities we suggest you entrust installation to an experienced workshop or mechanic. Installation time can take approximately 1-2 hours depending on your familiarity with the bike. All directions are given as if you are sitting on the bike: e.g. Left = gear change side. The installation of your TMR exhaust is straightforward but please be sure to read the instructions carefully, as they will help you get the job done quickly and easily. A fitting video is also available on our website which can be a helpful tool when used with these written instructions. I strongly recommend you watch the video for extra hints and tips on how to complete the job quickly and thoroughly. Tool List : M4 socket head wrench M6 socket head wrench M10 hex head wrench M12 hex head wrench M13 hex head wrench (x2) M14 hex head wrench Light oil Parts List: 1 x Right side Carbon Fiber Trim Piece 1 x Left side Carbon Fiber Trim Piece 1 x Muffler complete with Trim Bracket & Clamp 1 x Muffler Strap 1x Muffler Strap Bracket 1 x M8 x 35 hex head bolt, nyloc nut, 2 x washers 1 x M8 x 20mm spacer 2 x M6 x 10 button head bolts & M6 penny washer 1 x M6 penny washer 1 x Tie wrap 2
STAGE ONE DISASSEMBLY 1) Disconnect exhaust valve. a. Remove passenger seat. b. Remove upper cowl (4 x socket heat bolts and slide to rear.) c. Remove rider s seat. (Two hex head bolts.) d. Remove servo motor. (Two cross head bolts.) e. Slide rubber boots off cable adjusters, release locking nut and screw in adjuster to provide cable free play f. Pry off cable retainer from servo and remove cables g. Replace all above in the reverse order 2) Remove stock muffler. a. Remove exhaust valve cover. (3 socket head bolts.) b. Remove muffler: (Slacken clamp, remove bolt to passenger foot rest hanger.) c. Remove exhaust valve cable cover. (1 socket head bolt at rear close to rear tire.) d. Remove exhaust valve cables: Pull cables down through rear sub frame. 3) Release muffler box clamp to the headers, remove muffler box mounting bolt and slide box to rear off the header. 4) Remove top hat spacer and rubber bushing from chassis muffler mount. 3
5) Remove bolt from behind riders footrest and put to the side for use later. 6) Remove nut from rear suspension linkage located on left hand side; use 14mm hex head socket. STAGE TWO ASSEMBLY 1) Place muffler strap bracket over rear suspension linkage bolt with the angled end pointing down and to the right hand side of the bike. Replace nut and tighten securely 2) Use a little light oil on the slip joint of the muffler then push muffler onto the header as far as it will go. At this stage, tighten the muffler clamp enough so you can just rotate the muffler. 3) Align muffler strap with tabs to the right hand side and slide strap over muffler. Align the bolt holes in the strap with the mounting bracket. 4) Push M8 x 35 hex head bolt & washer through strap mounting bracket hole at the strap end. Place the 20 mm spacer between the strap and the mounting bracket and engage threads through the M8 washer and M8 Nyloc nut on back side of the bracket. Do not tighten at this stage. 4
5) Test fit the right hand carbon trim panel by sliding it under rear of stock fairing; the top mounting tab should be behind the foot rest plate and the muffler exit should protrude through the hole in the trim panel. 6) Place large dia. M6 washer supplied with the kit over the M6 bolt you removed from the rear of the brake pedal. From the left hand side, push bolt through hole in the trim top mounting tab and screw into the back of the rear brake pedal finger tight. 7) Push together front of trim panel and rear of stock fairing side panel. Screw in rear panel mounting bolt finger tight. Push M6 button head bolt & M6 penny washer through bottom rear trim panel mounting tab and screw in finger tight to mount on rear of muffler 8) Rotate muffler to place the exit centrally in the hole in the trim piece. It may also be necessary to pull the muffler back on the headers to gain the necessary clearance. Place the muffler so there is no contact between the exit and the trim panel. 9) Once satisfied with the location of the muffler, remove the trim and tighten the strap bolt and muffler clamp. 10) Re-mount the trim and check position of exit once again. Please be patient at this stage. Things can change when the bolts are tightened and it may be necessary to repeat this whole process again to get the perfect alignment. If you do have to repeat the process this might be a good time for a tea break! When satisfied with the alignment, tighten muffler clamp to 25 ft/lbs. Then tighten bolts in the following order: a) Rear fairing panel b) Top trim mounting tab c) Bottom rear trim mounting tab 5
11) Mount up left hand carbon trim panel behind rear of stock fairing panel. Screw in stock bolt finger tight. 12) Align the hole in rear trim mounting tab with trim bracket on the back of the muffler. Push M6 button head bolt & M6 penny washer through mounting tab and screw in finger tight 13) Check fit of trim panel and when satisfied tighten both front and rear mounting bolts. Now, stand back and take a moment to admire the results of all your hard work. All that remains is to fire her up and go for a spin. After running the bike for approximately 100 miles go over all fasteners and check for tightness-pay particular attention to tighten muffler clamp to 25ft/lbs. TMR recommends the use of Loctite and safety wire in all racing applications. If you experience any problems with the fitment of your TaylorMade Exhaust components or these instructions, the technicians at TaylorMade will be pleased to help. Just give us a call. Safe Riding, Paul Taylor 6
Proper care guidelines for your TaylorMade Exhaust All components of your new exhaust are fabricated from thin wall stainless steel so it will never rust. The black finish is a baked-on ceramic coating which only requires washing with soap and water to help keep it clean. To keep your carbon fiber looking new, we recommend a regular application of Turtle Wax s Color Magic in black. The muffler has an absorption design which relies on a fiberglass packing to absorb noise, heat and vibration. Over time the packing will degrade and will require replacing to maintain sound absorption quality and integrity of the muffler. In normal use repacking will be necessary every 6000-7000 miles. Extended periods of use at high RPMs will significantly reduce this service interval. A sure sign that repacking is required is when there is a noticeable increase in sound level. When your muffler needs servicing please contact our service team here at TaylorMade, who will be pleased to inspect and refurbish your muffler at a minimal cost. WARRANTY AND LIMITATIONS Regarding products sold by TaylorMade Racing Inc. (TaylorMade) e.g., exhaust systems, composites, billet parts, etc., TaylorMade warrants these products against defects arising out of failure due to material and/or workmanship for a period of 1 year from the date of purchase regardless of actual in service date. This warranty is limited to the repair or replacement of the item solely at the discretion of TaylorMade. Such repair or replacement will be determined based solely on TaylorMade s evaluation of the item s intended and actual use.** Regarding products purchased from TaylorMade but not manufactured by TaylorMade, NO WARRANTIES WHATSOEVER are granted or implied. Any and all claims regarding items sold by TaylorMade but not manufactured by TaylorMade are to be referred to and disposed of by the actual manufacturer. Claims regarding these items may be administered by TaylorMade or referred to the actual manufacturer at TaylorMade s discretion. EXCLUSIONS This warranty does not cover finishes such as plating or paint nor their failure due to discoloration from heat, weathering, or abuse. Nor does it cover any failure due to damage arising out of improper installation, crash damage or incompatibility with other components. In any event, TaylorMade accepts no liability for any damage to vehicles or persons arising out of the use and/or abuse of a vehicle equipped with TaylorMade components, nor will TaylorMade accept liability for damage to injury or persons from the use or abuse of the product itself, whether direct or indirect, voluntary or involuntary. TaylorMade will not be responsible for any dispositions made by dealers or distributors of products. TaylorMade will not be responsible for any labor charges incurred by the customer for the installation or removal of the TaylorMade component or changes arising out of the collateral damage to the vehicle or persons while installing, removing, or using any item purchased from or supplied by TaylorMade whether manufactured by TaylorMade or not. RETURN POLICY TaylorMade will not be responsible for any shipping charges by the purchaser in returning the part to TaylorMade for evaluation. A return authorization number and a copy of the purchaser s invoice or receipt must accompany all returns. Parts returned without authorization may be refused. DISCLAIMER TAYLORMADE EXHAUST SYSTEMS, ENGINE PARTS, OR ANY PART WHICH MAY EFFECT EMISSION REGUALTION COMPLIANCE ARE FOR OFF HIGHWAY USE ONLY AND ARE NOT FOR SALE OR USE ON CALIFORNIA POLLUTION CONTROLLED VEHICLES OR IN OTHER STATES WHERE POLLUTION CONTROL LAWS APPLY. SUITABILITY OF APPLICATION IS THE SOLE RESPONSIBILITY OF THE PURCHASER **Failure to abide by the care guidelines outlined in the installation guide, will void any warranty terms listed above. Mufflers returned for refurbishment under warranty will be subject to inspection by TaylorMade technicians. If upon inspection our technicians deem that damage has occurred due to neglect, the customer will have the option to pay a refurbishment fee or to ship the muffler to their return address. 7